Summary of Contents for DAELIM S-FIVE

HOW TO USE THIS MANUAL CONTENTS This manual describes effective maintenance procedure for the S-Five manufactured by DAELIM Motor Co., Ltd. To ensure safety and optimal operating conditions of the vehicle, carry out regular inspections according to the SERVICE INFORMATION maintenance schedule (Section 2).

8. Flammable nitrogen gas is generated during charging the battery so charging must be performed in well-ventilated area and free of the open fire and spark. SERVICE RULES 1. Parts and lubrication oil must be DAELIM genuine or 2. Before maintenance, remove deposit or dust from the recommended parts.

SERVICE INFORMATION 3. Store the parts of each system discriminatively to install 4. After removing gasket, O-ring, piston pin clip and cotter each part in the right place. pin, always replace them with the new one. When removing the snap ring, it can be easily missed after transformation or installation.

SERVICE INFORMATION 11. Maintenance needed to use the specialized tools must 12. Never reuse the ball bearing removed with the ball performed with the right tool. applied pressure when removing press-fitted the bearing. 13. Check the smooth rotation of inner or outer race of the 14.

SERVICE INFORMATION 19. Install the oil seal so that the manufacturer marked 20. Connect the tube until the tube fully inserted in the surface directs outer surface.(direction not covered joint. Install the clip if it is supplied. Replace the tube with oil) having slacked end.

SERVICE INFORMATION CAUTION WHEN WIRING •Each cord must be connected depending on its color. •When measuring voltage or resistance of the cord When connecting different cord, attach color tube terminal using tester, contact the tester plug behind of around the connector. Connect the coupler to the the coupler.

SERVICE INFORMATION •Turn off the main switch before connecting/dis- •When disconnecting the coupler, disconnect it while connecting. holding the coupler body. Pull while holding the wire •Release the lock to disconnect the lock of the coupler. harness cord and do not remove the coupler connection. •The lock of the coupler has two types according to releasing method(press type and pull type) so release it properly according to the shape.

SERVICE INFORMATION •Insert the connector until the vinyl cover is fully •When removing T-start, broaden the groove of T-start inserted into the terminal. using the wiring driver and release the torque. •The opening of the vinyl cover must face at the ground •Connect the harness and the hose to T-start and then direction but in case of the plain connector, the draining insert until the groove is locked.

SERVICE INFORMATION •In case that the wire harness is contacted with the end or •The wire must not hang down or be pulled excessively. the sharp edge, protect both parts with tube or tape. NOT TO PULL! •If necessary, lock the wire harness properly. •When mounting parts, make sure that the wire harness is not pressed by the parts.

SERVICE INFORMATION SYMBOLS The following symbols appear in this manual and offer cautionary suggestions which need to be heeded when performing maintenance work on the vehicle. SYMBOL CAUTION SYMBOL CAUTION Indicates an important step or operation. Indicates special caution needed. CAUTION Possibility of resulting in minor WARNING...

INSPECTIONS/ADJUSTMENTS CARBURETOR IDLING ● Stand the vehicle on the main stand. ● Heat the engine to make accurate idling inspection and adjustment. ● Verify all engine adjustments satisfy specifications. Make adjustments, if necessary. ● Turn the throttle stop screw and make adjustments to prescribed idling speed.

INSPECTIONS/ADJUSTMENTS REAR BRAKE FREE PLAY ADJUSTMENT ● Turn the adjuster nut to adjust the free play. ● After initial adjustment, check the operation of the rear brake light switch. Make additional adjustments, if necessary. ADJUSTER NUT HEADLIGHT ADJUSTMENT ● Adjust the headlight beam level by operating the adjusting screw located on the upper side of the front fender.

INSPECTIONS/ADJUSTMENTS SUSPENSION NOTE •Do not ride motor cycle with an unsatisfactory suspension. Loose or worn suspension parts will lead to deterioration in the vehicle’s safety and operation efficiency. FRONT WHEEL ● Hold the brake lever, and compress the front cushion up and down several times to check the operating conditions.

INSPECTIONS/ADJUSTMENTS ● Check the tread depth at the tire center. ● If the tread depth has reached the service limit, replace the tire. SERVICE LIMIT : 4.0mm 7.5mm STEERING HEAD BEARING NOTE •Check the cable if it interferes with the handle operation.

LUBRICATION SYSTEM ADJUSTMENT CAUTION •Perform after inspection and adjustment of throttle CONTROL cable. LEVER ● Check to see if the matching mark of the oil pump body and control lever are aligned in a state where the throttle grip is completely rotated. ●...

LUBRICATION SYSTEM OIL PUMP/OIL TUBE ● Fill the oil tank with engine oil. ● Cap around the oil pump and the carburetor with dry cloth. ● Locate the end of the oil tube in the level lower than the oil tank and drain the oil to bleed the air. OIL TUBE ●...

LUBRICATION SYSTEM ● Connect the oil pump and then the carburetor quickly with the both ends of the tube pressed to avoid the air from entering. NOTE •Make sure that the tubes are arranged correctly. ● Start the engine. NOTE •Do not start the engine in the poorly-ventilated area.

LUBRICATION SYSTEM ● Remove the oil tank cap and fill the oil tank with oil to the level of the projected portion RECOMMENDED OIL : ULTRA 2 SUPER OIL ● Reinstall the oil tank cap and check to see if the pilot lamp turns off when the main swich is turned on.

FUEL SYSTEM TROUBLESHOOTING Back firing The vehicle does not start. ● Ignition system is damaged. ● No gasoline in fuel tank. ● Mixture is too lean. ● Fuel is not coming out of carburetor. ● Too much fuel is flowing into cylinder. ●...

FUEL SYSTEM CARBURETOR CLEANING ● After removing all parts, blow open air and fuel passages in the carburetor body with compressed air. CAUTION •Cleaning the air and fuel passages with a piece of wire will damage the carburetor body or fuel pump. ●...

FUEL SYSTEM ● Connect the battery to the auto bystarter terminals and wait for 5 minutes. ● Insert a vinyl tube into the fuel enrichening circuit and blow into the tube. ● Air should not flow into the circuit. If air flows into the circuit, replace the auto bystarter.

6. ENGINE REMOVAL/INSTALLATION SERVICE INFORMATION ENGINE REMOVAL/INSTALLATION ENGINE HANGER LINK REMOVAL SERVICE INFORMATION GENERAL SAFETY NOTE •Use a jack to remove or install the engine. Support the motorcycle with a jack firmly, taking precautions not to damage the frame, engine, cable or harness. •Attach tape to the frame to protect it during the engine removal or installation.

● Replace the belt if the service limit is exceeded. SERVICE LIMIT : 16.5mm NOTE ·Use only a genuine DAELIM replacement drive belt. ·Do not get oil or grease on the drive belt or pulley faces. Clean off any grease or oil before reinstalling.

KICK STARTER/CONTINUOUSLY VARIABLE TRANSMISSION Clutch Shoe Inspection ● Measure the thickness of each shoe ; replace if the service limit is exceeded. SERVICE LIMIT : 2.0mm Movable Driven Face Spring Inspection ● Measure the free length of the driven pulley spring and replace if the service limit is exceeded.

8. CYLINDER HEAD/CYLINDER/PISTON SERVICES INFORMATION TROUBLESHOOTING FAN COVER, SHROUD REMOVAL CYLINDER HEAD/ CYLINDER/ PISTON SERVICE INFORMATION GENERAL SAFETY ● Take precautions not to damage the joint part with a driver when removing the cylinder, or not to damage the cooling pin by striking the cylinder too hard.

CYLINDER HEAD/CYLINDER/PISTON ● Remove the piston. ● Remove the piston ring. ● Remove the expander. ● Remove the needle bearing from the small end of the connecting rod. BEARING NOTE ·Do not damage or scratch the piston. ·Do not apply side force to the connecting rod. ·Do not let the clip fall into the crankcase.

CYLINDER HEAD/CYLINDER/PISTON Cylinder Wear Inspection ● Inspect the cylinder wall for scratches and wear. NOTE ·Inspect the area near T.D.C (Top Dend Center) carefully. This area is especially subject to wear due to the possibility of borderline lubrication fro heat and top ring compression.

9. TRANSMISSION/CRANKSHAFT/CRANKCASE SERVICE INFORMATION CRANKSHAFT REMOVAL TROUBLESHOOTING CRANKCASE BEARING REMOVAL 9-6 TRANSMISSION CRANKSHAFT INSTALLATION SERVICE INFORMATION GENERAL SAFETY ● This section describes how to remove the crank case and to maintain the transmission and the crankshaft. ● Always use special tools to change the drive shaft. Fix the bearing inner race, andn install the shaft. ●...

TRANSMISSION/CRANKSHAFT/CRANKCASE ● Measure the side gap between the connecting rod big end and the crank weight. SERVICE LIMIT : 0.6mm ● Check the vertical shaft play of the connecting rod big end from the X and Y direction. SERVICE LIMIT : 0.05mm CRANKCASE BEARING REMOVAL ●...

TRANSMISSION/CRANKSHAFT/CRANKCASE ● Apply clean engine oil to a new bearing, and assemble it to the crank case. ● Install a new final gear oil seal. CRANKSHAFT INSTALLATION ● Apply clean engine oil to the new R. crankshaft bearing, and press in the bearing into the R. crank case. TOOLS : DRIVER HANDLE A OUTER DRIVER 52x55mm DRIVER PILOT 20mm...

● Install the rear brake cable, front brake hose, speedometer cable to the handle cable guide. ● Apply DAELIM Bond A to the inside surface of the grip and to the clean surface of the left handle bar. Wait 3~6 minutes and install the grip.

FRONT WHEEL/FRONT FORK/STEERING WHEEL BEARING REPLACEMENT ● Install the bearing remover head and the remover shaft on the wheel, and remove the bearing and distance collar. NOTE ·Always replace bearings in pairs, and never use old bearings. TOOLS : BEARING REMOVER HEAD BEARING REMOVER ●...

FRONT WHEEL/FRONT FORK/STEERING ● Be sure that the bead is completely collapsed. ● In case of the tube type tire, insert the tire lever from the opposite side of the valve and raise the bead over the rim. ● On tubeless tires, insert the tire lever from the valve side and raise the bead over the rim.

FRONT WHEEL/FRONT FORK/STEERING RIM VALVE REPLACEMENT ● Cut off the rim valve at its base. ● Apply mild detergent solution to a replacement rim valve and insert it from inside of the rim. NOTE ·Be sure to use the recommended rim valve. ·Do not damage the valve hole.

FRONT WHEEL/FRONT FORK/STEERING ● If the tire has an light mark (yellow paint mark), install the tire with this mark aligned with the valve. ● If the tire has an arrow mark, install the tire with the mark pointing in the direction of rotation. ●...

FRONT WHEEL/FRONT FORK/STEERING ● After 3/4 of the bead has been installed, check the bead on the opposite side. Be sure it is still in the center of the rim. NOTE ·The last portion of the bead is more difficult to install.

FRONT WHEEL/FRONT FORK/STEERING NOTE ·For tubeless tires, you may hear a loud sound as the bead seats onto the rim. This is normal. ·For tubeless tires, if air leaks out from between the rim and bead, let the wheel stand with the valve at the bottom and put air in while pushing down on the tire.

FRONT WHEEL/FRONT FORK/STEERING ● Wrap the bottom case with a piece of cloth, and fix it to the vise. ● Apply screw locking agent to the socket bolt thread, and assemble the socket bolt to the fork piston. TORQUE VALUE : 2.0kgf·m NOTE ·When a vise is used to hold the bottom case, do not insert the case itself but insert the bracket.

FRONT WHEEL/FRONT FORK/STEERING ● Remove the upper ball race/ steering bottom cone race. TOOL : BALL RACE DRIVER NOTE ·Check all of the races and balls for damage or abnormal wear and replace as necessary. ·If the vehicle has been involved in a collision, the steering stem may be damaged.

FRONT WHEEL/FRONT FORK/STEERING ● Install the top cone race and the steering head top thread nut on the steering head. ● Tighten the top thread nut completely, and loosen by 1/8 turn. TORQUE VALUE : 1.0㎏f·m ● Check the top and bottom free play, and check for smooth left and right movement.

11. REAR WHEEL/BRAKE/SUSPENSION SERVICE INFORMATION 11-1 REAR BRAKE 11-4 TROUBLESHOOTING 11-2 REAR CUSHION 11-6 REAR WHEEL 11-3 SERVICE INFORMATION GENERAL SAFETY ● If the brake drum or lining is contaminated with oil, braking power will be lost. If contaminated with oil, clean the brake drum, and replace the brake shoe.

BRAKE SYSTEM ● If the brake bleeder is not used, do the following, ● First, fill the brake fluid up to the upper limit line. MASTER CYLINDER ● Connect the hose to the bleeder valve to receive brake fluid. ① Squeeze the brake lever completely loosen the bleeder valve 1/2 turn, and tighten it again.

BRAKE SYSTEM ● Loosen the 2 front brake caliper fixing bolts from the front fork. ● Remove the front caliper. ● To install a new brake pad into the brake, press the HANGER PIN piston to return to the original position. ●...

BRAKE SYSTEM BRAKE CALIPER INSPECTION Caliper Cylinder ● Check the caliper cylinder bore for scoring, scratches or other damage. ● Measure the caliper cylinder I.D. in X and Y axis at serveral points. ● Replace the caliper cylinder if the largest measurement is beyond the specified service limit.

BRAKE SYSTEM ● Install the primary cup with its concaved side toward the inner side of the master cylinder. ● Install the snap ring. TOOL : SNAP RING PLIERS CAUTION ·When installing the cups, do not allow the lips to turn inside out.

BATTERY/CHARGING SYSTEM NOTE ·Check with fully charge the battery which has the voltage between terminal of 13.0~13.2V. ·In case that the engine is started by the starter motor, measurement must be performed after accelating (charging) for 10 seconds. CHARGING CURRENT CHECK ●...

BATTERY/CHARGING SYSTEM HEADLIGHT VOLTAGE INSPECTION ● Remove the front cover. ( 3-5) CAUTION ·Check voltage with the headlight coupler connected. ● After starting the engine, place the dimmer switch to HI and check the voltage between the blue (+) and green (-) wires of the headlight coupler.

IGNITION SYSTEM TROUBLESHOOTING Spark plug does not emit sparks. ABNORMAL STATE POSSIBLE CAUSES (START FROM 1 AND GO THROUGH LIST IN ORDER) 1. Using a tester with a low internal resistance. 2. Cranking speed is low. - Battery is low or kick power is weak. 3.

IGNITION SYSTEM PULSE GENERATOR NOTE ·Inspect with the spark plug assembled and while there is compression pressure. ● Remove the CDI unit. ( 14-7 ) ● Remove the coupler from the CDI unit and connect the peak voltage adaptor to the pulse generator wire (blue/ yellow and green) of harness coupler.

IGNITION SYSTEM IGNITION TIMING INSPECTION TIMING LIGHT NOTE ·As a CDI device is used in this vehicle, there is no need for adjusting ignition timing. If ignition timing problems occur, inspect the CDI unit and the AC generator and replace if any malfunctions are found in the devices.

15. STARTING SYSTEM SERVICE INFORMATION 15-1 STARTER MOTOR 15-4 STARTING DEVICES LOCATION 15-2 STARTER RELAY INSPECTION 15-7 TROUBLESHOOTING 15-3 STARTER PINION GEAR INSPECTION 15-7 SERVICE INFORMATION GENERAL SAFETY WARNING ·When performing maintenance on the starter motor and related parts, turn the main switch to OFF. There is the danger of the starter motor unexpectedly operating if the main switch is not turned to OFF.

STARTING SYSTEM TROUBLESHOOTING Starter motor does not rotate (No response from starter motor). ● Check to see if the fuse is burned out. With the main switch turned to ON, squeeze Remove the starter motor “⊕” wire, connect the brake lever. In this state push the starter it to the battery “⊕”...

STARTING SYSTEM ● Check the commutator for : -Damage or abnormal wear. → Replace with a new one. -Discoloration of the commutator bar. → Replace with a new one. -Metallic debris between commutator bars.→ Clean it off. COMMUTATOR ● Check for continuity between pairs of commutator bars.

STARTING SYSTEM ● Insert the brush spring into the brush holder and install the front bracket. NOTE ·Insert the brush spring with care so that it does not lean in the holder. BRUSH HOLDER ● Apply grease to both ends of the armature shaft. GREASE ●...

STARTING SYSTEM STARTER RELAY INSPECTION ● Remove the luggage box. ( 3-3 ) ● When battery voltage is applied between the starter relay green/yellow wire and yellow/red terminals, there should be continuity between the red and red/white terminals. The terminals are distinguished by the corresponding wire color of the wire harness connector.

LIGHTS/METER/SWITCHES REAR WINKER BULB REPLACEMENT ● Press the winker lens groove and open the winker lens using plain screwdriver. ● Remove the bulb from the socket, replace with new bulb. ● Install in the reverse order of removal. NOTE ·Pay attention not to damage the lens. ·Do not apply excessive force when removing the lens.

LIGHTS/METER/SWITCHES ● Roose the 3 tapping screws securing the speedometer and the rear handle cover. ● Disconnect the R/L wiring. ● Remove the speedometer assembly. ● Install in the reverse order of removal. NOTE ·Check the each switch for proper operation. ·The wire and cable must be connected accurately.